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A Contribution to the Realisation of the Energy Transition: Optimisation of Thermochemical Energy Conversion Processes for the Flexible Utilisation of Hydrogen-based Renewable Fuels Using Additive Manufacturing
Deutsche Forschungsgemeinschaft (DFG)
Accordingly, this Priority Programme takes a new interdisciplinary approach that links the competences of combustion science and additive manufacturing (AM). The hypothesis of the SPP is that only a comprehensive understanding of combustion fundamentals as well as the integration of modern 3D manufacturing processes and simulation-based design as well as the use and adoption of AM-suited materials can enable the simultaneous improvement of flexibility, efficiency, and emissions in thermochemical energy conversion processes.
For structuring the relevant research fields, it is important to establish the necessary interrelationships among combustion science and AM, but also to address fundamental questions of the individual disciplines. For thermochemical energy conversion, the relevant processes occur on length and time scales that span several orders of magnitude that require consideration of laboratory and system scales. For AM, burner and combustion chamber design (e.g., topology optimisation), sensor integration, and materials are important.
The overarching aims of the project are to develop domain-specific knowledge and methods, to create an interdisciplinary research field between combustion science and manufacturing, and to demonstrate the approach both computationally and experimentally. The specific goals of the Priority Programme include the advancement of methods, since the design of highly complex AM-manufactured burner and combustion chamber concepts and appropriately adapted operating strategies requires an integrated process using predictive simulation, AM, and experimental analysis.
Specific long-term objectives are
- establishment of high-temperature-resistant 3D-printed burner and combustion chamber concepts on a laboratory scale using multi-material processes and new concepts for temperature control of high-temperature-resistant materials (e.g., nickel-based superalloys, refractory metals),
- automation and further development of sensor-integrated measurement technology,
- automatic optimisation of combustion devices for industrial implementation with fuel flexibility up to 100% hydrogen or hydrogen/ammonia mixtures,
- computer-aided upscaling of thermochemical-energy conversion plants for the energy transition.
The first period focuses on fundamental aspects and development of concepts. This includes
- experimental databases for kinetic modelling,
- physical knowledge and databases from basic laboratory experiments and direct numerical simulations on the internal structure of reaction zones, flame stabilisation, flame flashback, intrinsic instabilities, and pollutant formation; first modelling approaches,
- establishment of comprehensive, well-documented, and shared data sets for system-scale standard configurations with first AM-manufactured burners (gas turbine, industrial burner),
- derivation and first implementation of necessary development steps (design, material, process) in the field of AM (based on the requirements from combustion technology) addressing the specific requirements of hydrogen-based fuel combustion,
- development of specialised, fuel-flexible, and scalable burners and combustion chambers for experimental investigations with, e.g., sensor integration and/or channels for gas extraction by AM.
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